Many small gas tank leaks can be repaired using an epoxy compound, often without removing the gas tank from a vehicle. However, the precise steps involved in a gas tank repair vary according to the design of the vehicle and the severity of damage to the tank.
Small leaks in a gas tank can be fixed with repair epoxy compounds specifically designed for gas tanks, provided it is possible to access the leak. Jack stands are required to get under the vehicle, along with rubbing alcohol or another de-greasing chemical. After draining the tank and locating the leak, it is important to use the de-greasing agent and sandpaper to clean around the leak. The repairer should mix the sealant epoxy following the manufacturer's instructions and form a cone-shaped plug to insert into the leak. Once the epoxy sets, it is necessary to fill the tank and check to make sure the leak has stopped.
Sometimes the damage to a gas tank is large enough that replacing the entire tank is necessary. In cases where the leak is inaccessible, replacement is also ideal. For some models, it is necessary to remove the gas tank to service a fuel pump inside the tank.